My 2004 Journey (bought new) came with a Dimensions 2000 inverter/converter. The unit failed after about 2 years. I was plugged into a 50 amp service with no load on the inverter when I smelled the odor of something electrical burning. After pulling the unit, I found one of the circuits boards had burned.
The unit was repaired by Dimensions.......NOW!!! The unit has failed again. This time while driving down the road with no load on the Inverter.

I am at loss as to why I could have two failures in 5 years. Has anyone else had this kind of loss?

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I understand how you feel. I currently have my 3rd unit installed since 2005. However the last unit seems to be a winner. It has lasted for three years now without a problem, while the other two failed within a 16 month period.
Others have had their share of failures as well. It seems that Dimensions has done some redesign work as they pointed out when I discussed my frustration with them when the second unit failed. Time will tell. My problems were that my batteries were getting damaged. So far the batteries are holding up as well. You might give Dimensions another try which is the least expensive option, or bite the bullet and replace it al together with a Xantrex RS2000 for instance. That will be my next step should my 3rd unit fail.

My 2004 Journey (bought new) came with a Dimensions 2000 inverter/converter. The unit failed after about 2 years. I was plugged into a 50 amp service with no load on the inverter when I smelled the odor of something electrical burning. After pulling the unit, I found one of the circuits boards had burned.
The unit was repaired by Dimensions.......NOW!!! The unit has failed again. This time while driving down the road with no load on the Inverter.

I am at loss as to why I could have two failures in 5 years. Has anyone else had this kind of loss?

Any suggestions as how to prolong the life on the next unit? HELP!!!

I can't answer your question but I was, at one time, an ASQC certified engineer in military/aerospace electronics. I CAN tell you that everything fails eventually. the task of identifying failures and predicting longevity is nearly impossible. If our products failed, no one wanted to go out in space to repair them. Therefore, we tried our darndest to make sure they lasted.

We destructively tested, and rated tested every product to one degree or another. You can build 1000 units, all made from the same parts all made at the same time. They go through life testing and pass. Then you out them in the field and one fails out of the box and another lives as long as it is used.

Our Demented inverter failed 3 years ago after ruining our batteries and ( we suspect)causing some appliances to bite the dust. The rebuilt one seems to be OK but if it goes there will be another brand to replace it. Do a search, many have had problems with Demensions.